Metal framing members

ABSTRACT

Methods of producing a metal framing member having a plurality of screw tunnels, metal framing members prepared using such methods, and metal framing systems using such metal framing members. The metal framing sheet in one aspect has an undulating surface where projections and associated depressions are formed on opposite sides of the metal sheet in a coordinated pattern. The metal sheets may be produced through the use of rolls having a variety of patterns and/or projections and recesses that the sheet metal is pressed between. In one aspect the rolls have a honeycomb pattern that is advantageous in many ways including enhanced screw retention, surface penetration, acoustical and thermal performance, sheet rigidity and load bearing capability.

BACKGROUND OF THE INVENTION

The invention of the present application is directed to the manufacture of metal sheet material and the material itself; including metal framing, as may be used in building construction, among other applications. The invention is more particularly directed to metal framing members (i.e., metal studs) having screw tunnels, also referred to as “screw sleeves” or “screw sockets”, for securely fastening materials (i.e., sheet rock or plywood, among others) to the studs during construction as well as the processes and structures for forming the sheets of material and the metal frame segments.

SUMMARY OF THE INVENTION

Gypsum board, cement board, insulation panels, plywood, OSB board, nail board, fire/water/impact resistant wall panels (i.e. DragonBoard), stucco and synthetic stucco systems, interior and exterior fascia materials, metal stiffeners, and metal framing may be fastened to commercially available metal framing sections using screws. When attaching materials to the metal framing member, screws (such as penetrating metal screws) are utilized. The contact between the screw and the metal framing anchors the screw, permitting a material to be sandwiched between the framing and the head of the screw. In conventional systems, only a limited surface area of the sections contacts the screws. By increasing the contact area between a screw and the metal framing, the “surface screw penetration” is improved to more firmly anchor the screw, and consequently more securely fasten a material to the metal framing. Additionally, the secure fastening of building materials is a consequence of the improved screw retention disclosed by the invention. Screw retention is a significant performance indicator and demonstrates the resistance of the screw from stripping when applied at high speeds with a screw gun. In one aspect, screw retention is measured by an amount of force required for “pull-out” of the attached screws. ASTM 645 is a standard associated with this method of testing and measurement.

Conventional sheet metal material is enhanced by processes of the invention that form undulating surfaces throughout the entire sheet or a portion thereof. Advantages of weight reduction and cost savings by using less material (thinner sheet), improved acoustical and thermal performance, and rigidity and load bearing ability both transversely and longitudinally are just a few of the benefits of the disclosed invention. Certain aspects of the present invention are directed to the metal framing members comprising a plurality of screw tunnels. In some embodiments, the metal framing members include a structural portion (web) and at least one flange portion, whereby at least one or more screw tunnels may be formed in at least one of the structural portion and the flange. According to the invention, in other embodiments screw tunnels are formed in both flanges. In some embodiments, the metal framing member may have a top surface and a bottom surface, and the screw tunnels may protrude from at least one of the top surface and the bottom surface.

Some aspects of the present invention are directed to methods of producing a metal framing member including, forming a plurality of screw tunnels in at least a portion of a top surface or a bottom surface of a metal sheet. The tunneled metal sheet may then be formed into a metal framing member. In certain embodiments, the screw tunnels may be formed by embossing or pressing. In some embodiments of the present invention, the metal sheet may be embossed using embossing rolls to form screw tunnels. Embossing rolls known in the art may be used.

Certain embodiments of the present invention are directed to the methods of attaching a peripheral material to the metal framing member. A screw (i.e., a penetrating metal screw) may be screwed through a peripheral material and into a screw tunnel in the metal framing section. According to certain aspects of the invention, the screw tunnel comprises an interior surface and the screw may be brought into contact with the interior surface of the screw tunnel, wherein the surface screw penetration is significantly improved compared to prior art systems and screw retention is superior.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1( a) depicts a plan view of one embodiment according to the invention showing projections on one side of a material sheet;

FIG. 1( b) is a cross-section view of the embodiment shown in FIG. 1( a);

FIG. 2( a) depicts a plan view of another embodiment according to the invention showing projections formed on both sides of a material sheet;

FIG. 2( b) is a cross-section view of the embodiment shown in FIG. 2( a);

FIG. 2( c) is a perspective view of the embodiment shown in FIG. 2( a)

FIG. 3 depicts a structural member with screw tunnels in a portion of a web according to one aspect of the invention;

FIG. 4 depicts a structural member with screw tunnels in a portion of a flange according to another aspect the invention;

FIG. 5 depicts a structural member with screw tunnels covering both the web and flanges; and

FIG. 6 depicts one embodiment of a screw tunnel according to the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Certain embodiments of the present invention are directed to metal framing members comprising a plurality of screw tunnels (screw sleeves or sockets). The metal framing member (i.e., metal stud) may have a variety of different cross sections and may be structural (e.g., weight carrying/load bearing) or nonstructural.

In some embodiments the metal framing section may include at least one of galvanized, aluminized, galv-alume, galv-annealed, electro-galvanized, and pre-painted steel. When painted the paint can be applied over bare steel (cold rolled and hot rolled) but is typically applied over one of the previously listed finishes. The sheet material is preferably mild steel, which may be galvanized or otherwise coated for protection against corrosion. High Strength Steels are also employed according to the invention. Pre-painted galvanized is a popular combination. Many of the known materials and coatings may be used for metal stud applications due to their common availability and suitability for the manufacture of metal stud and metal framing members. In some aspects, metal framing is able to employ these materials in conditions of prime, secondary, reject or surplus provided the materials are within the intended specifications of thickness, formability and corrosion resistance. Certain materials, such as aluminum and stainless steel, may be used but are generally too costly for this application. The metal framing member may have a thickness of between 0.01″ and 0.140″ in some embodiments. In certain aspects, the metal framing member may have a coating comprising at least one of paint, resin, and lacquer.

The metal framing member may be produced by shaping a metal sheet. The metal framing member may be formed to comprise a structural portion and at least one flange. The structural portion may contribute to the ability of the metal framing member to withstand a specific load. At least some of the screw tunnels may be formed in the web of the metal framing member and/or in a flange. In some embodiments, screw tunnels are formed in only one flange. In certain aspects, screw tunnels are located in both flanges.

According to the invention, the amount and location of the embossing may be a design and/or performance consideration. For example, the sheet material may be embossed only in the web or flanges or only in a portion of the web or flanges. Such a design may reduce tooling costs and maintenance and this is typically where the screws are used to engage the sheet material. In these embodiments, the web sections may be stiffened through the use of partial or complete embossing, stamping or corrugations to provide additional strength and/or to compensate for a reduction of the sheet material thickness.

The present invention relates to sheet material having on one side or both of its faces a plurality of rows of projections whereby each projection is formed by deforming the sheet material locally to leave a corresponding depression at the opposite face, such that the mass or thickness of the material required for a particular application may be reduced. In one aspect the metal framing sheet has an undulating surface where projections and associated depressions are formed on opposite sides of the metal sheet in a coordinated pattern such that projections from one side are integrated with projections formed from the other side. Of course, the patterns need not be coordinated or may be random. In one embodiment, rows of alternating projections and depressions extend in one direction wherein straight lines can be drawn on a surface of the material between adjacent ones of these rows. Perpendicular rows of alternating projections and depressions may also extend wherein a second group of straight lines can be drawn on the surface of the material. In some of the embodiments, the array of projections on one face of the material is substantially identical with the array of projections on the other face of the material. The undulating surface is formed in the sheet metal by pressing the material past its yield point. Such an embodiment results in “stretching,” rigidizing,” and increasing the strength of the original material both by its design and by work hardening of the metal. The stiffening effect associated with deep metal embossing is one of the advantages of the current invention.

The screw tunnels may be formed by embossing or pressing a metal sheet according to certain aspects of the invention. The metal sheets may be produced through the use of rolls having a variety of patterns or projections and recesses that the sheet metal is pressed between. In certain aspects, a metal sheet may be embossed using power-drive, mated embossing rolls. The sheet metal may have a top surface and a bottom surface, and the screw tunnels may be formed to protrude from at least one of the top or bottom surface. Each screw tunnel may have a circular, hexagonal, octagonal or other geometric cross-section. In one aspect the rolls have a honeycomb pattern. The projections/recesses of the rolls and the corresponding screw tunnels may be rounded, cone shaped, edged, flat, fluted, etc. as long as the tunnels meet the screw retention and surface penetration requirements, and the other precepts set forth by the invention. In one preferred embodiment a honeycomb cross-section is combined with a conical projection/recess. In certain embodiments, a hole or opening may be constructed or formed at the peak of the projection or projections or elsewhere in the surface area through the use of rollers or via other means. Such a design has many advantages including enhancing screw starts, acoustical dissipations, and holding less moisture.

In one aspect of the invention, the objective of the screw tunnel's initial and tapering dimensions is to correspond with the dimensions of the body and threads of the metal screws typically used in the application of affixing building materials to metal studs. The screw body dimensions are measured in terms of the Major Diameter, the measurement of the outside diameter of the screw threads; and the Minor Diameter, the measurement of the screw body inside of the threads.

The screw tunnel dimensions have a purpose and similarity to the “pilot hole” dimensions used in preparing wood studs, as the interior surface of the screw tunnel provides for the metal to form around the screw body and control the breakage and splitting of the sheet metal as the screw pierces the metal thickness of the framing member and the metal forms around the body of the screw.

The Major and Minor dimensions of screws associated with Metal Framing usage are typically expressed in the industry standardized numerical sizing of #0, #1, #2, #3, #4, #5, #6, #7, #8, #9, #10, etc. and larger. Numbered sizes of #6, #7 and larger are typical for usage with metal framing. In addition to the numbered size, a thread type is also specified, such as “coarse” or “fine” or “high-low”, which primarily affects only the Major Diameter and number of threads per inch, leaving the Minor Diameter consistent within the numbered type. The scope of the present invention provides for the correspondences on all screw types and sizes used for application with metal studs. The relationship of dimensions required is that the screw tunnel entrance diameter exists in a range of ratios from about 4/10ths to about 8/10ths to the Minor Diameter of the screw being applied.

For example, the #6 drywall screw in both “coarse” and “fine” thread design is among the most common used with non-structural steel studs, which are typically 0.040″ and lighter in parent metal thickness for the framing member. The #6 screw is designed with a Major Diameter of about 0.145″ and a Minor Diameter of about 0.102″. Therefore the screw tunnel may be present with an initial opening dimension of about 0.040″ ( 4/10ths) to 0.080″ ( 8/10ths) relative to the Minor Diameter of the screw body.

In another example, the #7 screw in both “coarse” and “fine” thread is designed with a Major Diameter of about 0.156″ and a Minor Diameter of about 0.113. Therefore the screw tunnel may be present with an initial opening of about 0.045″ ( 4/10ths) to 0.090″ ( 8/10ths).

By way of further example, the #8 screw in both “coarse” and “fine” thread is designed with a Major Diameter of about 0.170″ and a Minor Diameter of about 0.123″. Therefore the screw tunnel may be present with an initial opening of approximately 0.048″ ( 4/10ths) to 0.098″ ( 8/10ths).

This relationship of Minor Diameters to the Screw Tunnel opening dimensions exists throughout the full industry standardized range of screw sizes as described in the #6, #7 and #8 examples presented above.

The relationship between the screw size and the screw tunnel has an effect upon the screw retention and pull out values as the amount of contact area between the screw and the metal which it is penetrating increases. Pull out values will be further improved when the screw is pulled out, rather than screwed out, as the screw tunnel will collapse in the direction that the screw is being pulled, increasing the metal thickness embracing the screw body in the direction of the pull out.

Screw retention is improved with screw tunnel depth. In one preferred embodiment, the screw tunnel depth may be about 1.5× or greater than the original parent metal thickness and not less than about 0.030″ regardless of the parent metal thickness. A starting thickness of 0.0438″ (18 gauge) therefore requires a tunnel depth of about 0.065″; 0.0329″ about 0.049″; 0.025″ about 0.037″; 0.0179″ about 0.026″; 0.015″ about 0.022″; and 0.012″ about 0.018″. In this preferred embodiment, an increase in screw retention of about 20% is achieved by the use of the screw tunnel when compared to flat material of the same average thickness not employing the inventive screw tunnel design.

Certain aspects of the invention are directed to methods of producing a metal framing member (i.e., metal stud) including, forming a plurality of screw tunnels in at least a portion of a top surface or a bottom surface of a metal sheet, and shaping the tunneled metal into a metal framing member by means roll forming, press brake forming or other conventional methods of cold forming metals. A coating material, such as paint, resin, or lacquer, may be applied to the metal framing member, in some aspects of the present invention. A coating material may be applied by spraying, dipping, or rolling in some embodiments.

In certain embodiments the studs, including the screw tunnels, may be coated. A lacquer or other corrosion inhibitor may be applied alone or in combination with the coating as deep embossing may result in some cracking and stretching of the galvanized finish or other original coating applied to the parent metal. Additionally, embossed areas may hold water and therefore are preferably manufactured in a way to prevent against rust and other environmental problems. The coatings, when applied, dependent upon type and thickness, may improve screw retention.

As discussed above, the screw tunnels may be produced in the sheet material by using power-driven embossing rolls. Alternative methods of embossing include conventional stamping or rotary stamping.

Embossing rolls may be manufactured in a variety of ways including machining, direct casting, acid etching, laser cutting and other methods. The projections and recesses needed to produce the undulating sheet material, creating the plurality of screw tunnels may be arranged in a variety of forms according to the invention. A honeycomb or hexagonal shape is shown in FIGS. 1( a)-(b) in sheet 10. Screw 12 is shown inserted into one of screw tunnels 11 in sheet 10. A symmetrical projection design in which projections alternate between projecting to one side and the other side is shown in FIGS. 2(a)-(c). According to the principles of the invention, suitable sheets may be embossed with various patterns of different geometric shapes, allowing for variations in sheet rigidity.

Screws 22 are shown inserted into two of screw tunnels 21 of sheet 20. In one embodiment, the rolls are mounted for relative rotation about respective parallel axes spaced apart by a distance such that the projections on a first roll extend into the recesses between projections on the second roll. In this aspect, the rolls are driven at the same speed as the parent sheet metal is passed between the rolls.

According to the invention, in any of these methods of creating a honeycomb or alternate pattern through rolling, the resulting screw tunnel projections can be conical, cylindrical, or flat bottomed.

Certain embodiments of the invention are directed to methods of attaching a peripheral material to a metal framing member (i.e., metal stud) including, screwing a screw (i.e., a penetrating metal screw) through the peripheral material and into a screw tunnel. Each screw tunnel has an interior surface and during attachment of the peripheral material the screw may be brought into contact with the interior surface of the screw tunnel. The peripheral material may be gypsum board, cement board, insulation panels, plywood, OSB board, nail board, fire/water/impact resistant wall panels (i.e., DragonBoard), stucco and synthetic stucco systems, interior and exterior fascia materials, metal stiffeners, or metal framing, among others.

In an embodiment shown in FIG. 6, the interior dimensions of a screw tunnel of the present invention may be sized in accordance with a metal screw's minor and major diameters thereby increasing the surface area of the screw body engaging the interior of the screw tunnel and increasing the screw retention and surface screw penetration. In one aspect the conical depression of a screw tunnel forms a type of metal wrapping about the exterior body of the metal screw. Retention may be further improved by concavity of a screw tunnel, because the concavity must be pulled towards the neutral axis of the metal sheet material before failure will occur (i.e., screw stripping). The design and structure of the screw tunnels are such to avoid or minimize this type of failure.

In FIG. 6, metal sheet 70 may include screw tunnel 71. Dimension a at the top of the plate at the entrance to screw tunnel 71 may be roughly equal to about 40-80% of the minor diameter of the metal screw to be inserted into screw tunnel 71. For example, dimension a may be between about 40% and about 80% of the minor diameter, or between about 50% and about 70% of the minor diameter, or between about 55% and about 65% of the minor diameter of the screw to be inserted into the screw tunnel 71. The interior wall 72 of screw tunnel 71 may be beveled toward longitudinal axis 73 of screw tunnel 71 as shown. Dimension b is depicted as being the width of screw tunnel 71 at a distance from the top of the plate roughly equal to the thickness of metal sheet 70 prior to embossing.

In another embodiment, the screw tunnel 71 is defined as having a cross-sectional dimension b that is in a plane that is a distance equal to the thickness of the metal sheet prior to embossing as measured from the plane at which a screw enters the screw tunnel 71, and is about 0% to about 100% of dimension a depending on the depth of the screw tunnel. The screw tunnel 71 may have an interior surface that is tapered with respect to an axis of the screw tunnel from at least the plane at which the screw enters the metal sheet to a depth equal to a thickness of the sheet of metal prior to embossing.

The sheet material which results from the process is suitable for use on its own as a structural member, for example a post, beam or panel. The sheet material may be formed into a channel, angle, or other profile wherein the formed shape possesses one or more flanges and web. The surfaces or a portion of the surface of both the flanges and the web may have rows of projections and depressions. In one aspect, only a portion of the surface of the sheet material such as the flanges has projections and depressions. The invention is useful for the manufacture of studs used in stud and panel partitions and for channels (track) in which lower end portions and upper end portions are received.

As can be seen in the figures, the depressions/projections may be one-sided as in FIGS. 1( a)-(b) or present on both sides of the embossed surface as in FIGS. 2( a)-(c). In a preferred embodiment, the screw tunnel design is matched to the intended screw shape and size so as to effectively grasp the screw and engage it with a higher percentage of metal surface area of the material as compared to conventional arrangements. This provides improved surface screw penetration and increases the retention of the screw in the metal stud.

FIGS. 1( a)-(b) and 2(a)-(c) demonstrate the undulating surface of sheet metal material having honeycomb recessions/projections according to one aspect of the invention. The wrapping of the sheet material about the penetrating screw is also demonstrated. The sizes shown are for the depicted embodiments and, of course, a variety of sizes and shapes are contemplated according to the principles of the invention.

As shown, the embossed screw tunnel may be present on the entire surface area of the metal stud (both web and flanges) or limited to the web or limited to the flanges (those areas where metal screws are most commonly fastened) of the metal studs or limited to a portion of the flanges or web. FIG. 3 shows screw tunnels 51 in the web 52 of a channel 50, while FIG. 4 shows screw tunnels 61 in the flange 62 of a channel 60. FIG. 5 shows screw tunnels on both the flanges and web of a channel. Although a channel is shown, other structural members may be used, including but not limited to angles, square tubing, and I-beams. Corrugations and embossed patterns other than the screw tunnel may be used both transversely and longitudinally to further strengthen the metal stud in both transverse and longitudinal directions.

It should be noted that the elements depicted in the figures are not necessarily to scale and are exaggerated for illustrative purposes in certain instances.

In addition to the invention's enhanced screw retention, according to the principles of the invention a weight reduction of the material is achievable by allowing for a reduction in metal thickness due to the equal or greater properties achievable through the “screw tunnel” function when using lighter gauge material than employed in conventional systems. Acoustical performance is also improved compared to smooth metal studs as sound is dissipated through the embossed metal pattern. The thermal performance is also enhanced as the invention effects a slower transfer of both elevated and reduced temperatures by way of dissipation through the embossed metal surface. The invention also provides improved load carrying ability as a result of the embossed “rigidity”. The track/stud “fit-up” features are also superior to prior systems as the design of both the single sided and doubled sided “screw tunnels” provide for a mating of the embossed surfaces (embossed projections fitting into the corresponding embossed depressions). The result is a more secure fit and easier handling in the workplace.

Known prior art including U.S. Pat. Nos. 5,011,743, 5,689,990 and 6,183,879 and Swiss Reference CH-486,281 are incorporated by reference herein in their entireties. It will be apparent to one skilled in the art that various modifications can be made to the invention without departing from the spirit or scope of appended claims. 

1. A metal member for use in framing buildings and adapted to preferentially receive screws to attach peripheral materials to the metal member, comprising: a sheet of metal having one or more generally planar surfaces with at least a portion of one generally planar surface being embossed such that a plurality of screw tunnels having mating surfaces for substantial screw engagement are formed, wherein a cross-sectional dimension of the screw tunnel at a plane at which a screw enters the screw tunnel is between about 40% and about 80% of a minor diameter of the thread of a screw to be received by the metal member.
 2. The metal framing member of claim 1, further comprising a web and at least one flange.
 3. The metal framing member of claim 2, wherein one or more of the screw tunnels are in the web.
 4. The metal framing member of claim 2, herein one or more of the screws tunnels are in the flange.
 5. The metal framing member of claim 2, wherein both the structural portion and at least one flange have screw tunnels.
 6. The metal framing member of claim 1, wherein the metal framing member comprises at least one of the galvanized, aluminized, galv-annealed, electro-galvanized and pre-painted steel.
 7. The metal framing member of claim 1, wherein the metal framing member is made of steel.
 8. The metal framing member of claim 1, wherein the metal framing member has a thickness of between about 0.01″ and about 0.140″.
 9. The metal framing member of claim 1, further comprising a coating comprising at least one of paint, resin, and lacquer.
 10. The metal framing member of claim 1, wherein the plurality of screw tunnels has a circular, hexagonal, or octagonal cross section.
 11. The metal framing member of claim 1, wherein the plurality of screw tunnels has conical, cylindrical, or flat-bottomed projections.
 12. The metal framing member of claim 1, wherein the plurality of screw tunnels has a honeycombed cross-section with conical, cylindrical, or flat-bottomed projections.
 13. The metal framing member of claim 1, wherein the metal framing member has a top surface and a bottom surface, and the screw tunnels protrude from at least one of the top surface and the bottom surface.
 14. A method of producing a metal framing member comprising: providing a metal sheet having a top surface and a bottom surface, forming a plurality of screw tunnels having mating surfaces for substantial screw engagement, wherein a cross-sectional dimension of the screw tunnel at a plane at which a screw enters the screw tunnel is between about 40% and about 80% of a minor diameter of the thread of a screw to be received by the metal member.
 15. The method of claim 14, wherein the metal framing member comprises a structural portion and at least one flange.
 16. The method of claim 15, wherein one or more of the screw tunnels are in the structural portion.
 17. The method of claim 15, wherein one or more of the screw tunnels are in the flange.
 18. The method of claim 15, wherein both the structural portion and at lest one flange have screw tunnels.
 19. The method of claim 14, wherein the metal sheet is made of at least one of galvanized, galv-alume, galv-annealed, electro-galvanized, and pre-painted steel.
 20. The method of claim 14, wherein the metal sheet is made of steel.
 21. The method of claim 14, wherein the metal sheet has a thickness of between about 0.01″ and about 0.140″.
 22. The method of claim 14, further comprising applying a coating material to the metal framing member.
 23. The method of claim 22, wherein the coating material is a paint, a resin, or a lacquer.
 24. The method of claim 22, wherein the coating material is applied by spraying, dipping, or rolling.
 25. The method of claim 14, wherein the screw tunnels are formed by embossing or pressing.
 26. The method of claim 14, wherein the screw tunnels are formed by embossing, wherein the embossing is performed using embossing rolls.
 27. The method of claim 14, wherein the plurality of screw tunnels has a circular, hexagonal, octagonal or other geometric cross-section.
 28. The method of claim 14, wherein the plurality of screw tunnels has conical, cylindrical, or flat-bottomed projections.
 29. The method of claim 14, wherein the plurality of screw tunnels has a honeycomb cross-section with conical, cylindrical, or flat bottomed projections.
 30. The method of claim 14, wherein the plurality of screw tunnels have lengths of between 0.018″ and 0.250″.
 31. The method of claim 14, wherein the metal sheet has a top surface and a bottom surface, and the screw tunnels protrude from at least one of the top surface and the bottom surface. 